Caloric heat pump system

ABSTRACT

A caloric heat pump system includes a plurality of stages, a plurality of conduits and a plurality of flow restrictors. Each stage includes a caloric material disposed within a respective chamber of a plurality of chambers. Each conduit is coupled to a regenerator housing at a respective one of the plurality of chambers. Each flow restrictor is coupled to the regenerator housing or a respective one of the plurality of conduits. A related method for regulating fluid flow through a plurality of stages of a caloric heat pump is also provided.

FIELD OF THE INVENTION

The subject matter of the present disclosure relates generally tocaloric heat pump systems, such as magneto-caloric heat pump systems.

BACKGROUND OF THE INVENTION

Conventional refrigeration technology typically utilizes a heat pumpthat relies on compression and expansion of a fluid refrigerant toreceive and reject heat in a cyclic manner so as to effect a desiredtemperature change or i.e. transfer heat energy from one location toanother. This cycle can be used to provide e.g., for the receiving ofheat from a refrigeration compartment and the rejecting of such heat tothe environment or a location that is external to the compartment. Otherapplications include air conditioning of residential or commercialstructures. A variety of different fluid refrigerants have beendeveloped that can be used with the heat pump in such systems.

While improvements have been made to such heat pump systems that rely onthe compression of fluid refrigerant, at best such can still onlyoperate at about forty-five percent or less of the maximum theoreticalCarnot cycle efficiency. Also, some fluid refrigerants have beendiscontinued due to environmental concerns. The range of ambienttemperatures over which certain refrigerant-based systems can operatemay be impractical for certain locations. Other challenges with heatpumps that use a fluid refrigerant exist as well.

Magneto-caloric materials (MCMs), i.e. materials that exhibit themagneto-caloric effect, provide a potential alternative to fluidrefrigerants for heat pump applications. In general, the magneticmoments of an MCM will become more ordered under an increasing,externally applied magnetic field and cause the MCM to generate heat.Conversely, decreasing the externally applied magnetic field will allowthe magnetic moments of the MCM to become more disordered and allow theMCM to absorb heat. Some MCMs exhibit the opposite behavior, i.e.generating heat when the magnetic field is removed (which are sometimesreferred to as para-magneto-caloric material but both types are referredto collectively herein as magneto-caloric material or MCM). Thetheoretical Carnot cycle efficiency of a refrigeration cycle based on anMCM can be significantly higher than for a comparable refrigerationcycle based on a fluid refrigerant. As such, a heat pump system that caneffectively use an MCM would be useful.

Challenges exist to the practical and cost competitive use of an MCM,however. In addition to the development of suitable MCMs, equipment thatcan attractively utilize an MCM is still needed. Currently proposedequipment may require relatively large and expensive magnets, may beimpractical for use in e.g., appliance refrigeration, and may nototherwise operate with enough efficiency to justify capital cost.Additionally, manufacturing MCMs with uniform flow paths is challenging.Heat pump system having MCMs with different flow restrictions oftenprovide uneven fluid flow through the MCMs and reduced efficiency.

Accordingly, a heat pump system that can address certain challenges,such as those identified above, would be useful. Such a heat pump systemthat can also be used in e.g., a refrigerator appliance would also beuseful.

BRIEF DESCRIPTION OF THE INVENTION

The present subject matter provides a caloric heat pump system. Thecaloric heat pump system includes a plurality of stages, a plurality ofconduits and a plurality of flow restrictors. Each stage includes acaloric material disposed within a respective chamber of a plurality ofchambers. Each conduit is coupled to a regenerator housing at arespective one of the plurality of chambers. Each flow restrictor iscoupled to the regenerator housing or a respective one of the pluralityof conduits. A related method for regulating fluid flow through aplurality of stages of a caloric heat pump is also provided. Additionalaspects and advantages of the invention will be set forth in part in thefollowing description, or may be apparent from the description, or maybe learned through practice of the invention.

In a first exemplary embodiment, a caloric heat pump system is provided.The caloric heat pump system includes a regenerator housing having aplurality of chambers. The caloric heat pump system also includes aplurality of stages, a plurality of conduits and a plurality of flowrestrictors. Each stage includes a caloric material disposed within arespective chamber of the plurality of chambers. Each conduit is coupledto the regenerator housing at a respective one of the plurality ofchambers. A pump is coupled to the conduits of the plurality ofconduits. The pump is operable to circulate a working fluid through theconduits of the plurality of conduits and the stages of the plurality ofstages. Each flow restrictor is coupled to the regenerator housing or arespective one of the plurality of conduits. The flow restrictors of theplurality of flow restrictors are configured such that a flow rate ofthe working fluid through each stage of the plurality of stages isuniform.

In a second exemplary embodiment, a caloric heat pump system isprovided. The caloric heat pump system includes a regenerator housingwith a plurality of chambers. The caloric heat pump system also includesa plurality of stages, a plurality of conduits and a plurality of flowrestrictors. Each stage includes a caloric material disposed within arespective chamber of the plurality of chambers. Each conduit is coupledto the regenerator housing at a respective one of the plurality ofchambers. A pump is coupled to the conduits of the plurality ofconduits. The pump is operable to circulate a working fluid through theconduits of the plurality of conduits and the stages of the plurality ofstages. Each flow restrictor is coupled to the regenerator housing or arespective one of the plurality of conduits. The flow restrictors of theplurality of flow restrictors are configured such that a flow rate ofthe working fluid through each stage of the plurality of stages iswithin five percent of one another. The flow restrictors of theplurality of flow restrictors include at least one of an orifice, aneedle valve or a pinch valve.

In a third exemplary embodiment, a method for regulating fluid flowthrough a plurality of stages of a caloric heat pump is provided. Themethod includes flowing a fluid through each stage of the plurality ofstages, measuring a flow rate of the fluid through each stage of theplurality of stages and adjusting a plurality of flow restrictors suchthat the flow rate of fluid through each stage of the plurality ofstages is uniform.

These and other features, aspects and advantages of the presentinvention will become better understood with reference to the followingdescription and appended claims. The accompanying drawings, which areincorporated in and constitute a part of this specification, illustrateembodiments of the invention and, together with the description, serveto explain the principles of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

A full and enabling disclosure of the present invention, including thebest mode thereof, directed to one of ordinary skill in the art, is setforth in the specification, which makes reference to the appendedfigures.

FIG. 1 is a refrigerator appliance in accordance with an exemplaryembodiment of the present disclosure.

FIG. 2 is a schematic illustration of certain components of a heat pumpsystem positioned in the exemplary refrigerator appliance of FIG. 1.

FIG. 3 is a schematic illustration of certain components of the heatpump system of FIG. 2, with a first stage of MCM within a magnetic fieldand a second stage of MCM out of a magnetic field, in accordance with anexemplary embodiment of the present disclosure.

FIG. 4 is a schematic illustration of certain components of theexemplary heat pump system of FIG. 2, with the first stage of MCM out ofthe magnetic field and the second stage of MCM within the magneticfield.

FIG. 5 is a front view of an exemplary caloric heat pump of the heatpump system of FIG. 2, with first stages of MCM within magnetic fieldsand second stages of MCM out of magnetic fields.

FIG. 6 is a front view of the exemplary caloric heat pump of the heatpump system of FIG. 2, with first stages of MCM out of magnetic fieldsand second stages of MCM within magnetic fields.

FIG. 7 is a top view of a regenerator housing and MCM stages of theexemplary caloric heat pump of FIG. 5.

FIG. 8 is a top view of certain components of the exemplary caloric heatpump of FIG. 5.

FIG. 9 is a chart illustrating movement of a regenerator housing andassociated MCM stages in accordance with an exemplary embodiment of thepresent disclosure.

FIG. 10 is a chart illustrating operation of pumps to actively flowworking fluid in accordance with an exemplary embodiment of the presentdisclosure.

FIG. 11 is a schematic diagram illustrating various positions andmovements there-between of MCM stages in accordance with an exemplaryembodiment of the present disclosure.

FIGS. 12, 13 and 14 provide section views of regenerators according tovarious exemplary embodiment of the present subject matter.

FIG. 15 provides an elevation view of a pump according to an exemplaryembodiment of the present subject matter.

FIG. 16 provides a schematic view of an alternative exemplaryarrangement of stages of a heat pump system coupled to pistons of apump.

DETAILED DESCRIPTION

Reference now will be made in detail to embodiments of the invention,one or more examples of which are illustrated in the drawings. Eachexample is provided by way of explanation of the invention, notlimitation of the invention. In fact, it will be apparent to thoseskilled in the art that various modifications and variations can be madein the present invention without departing from the scope or spirit ofthe invention. For instance, features illustrated or described as partof one embodiment can be used with another embodiment to yield a stillfurther embodiment. Thus, it is intended that the present inventioncovers such modifications and variations as come within the scope of theappended claims and their equivalents.

The present subject matter is directed to a caloric heat pump system forheating or cooling an appliance, such as a refrigerator appliance. Whiledescribed in greater detail below in the context of a magneto-caloricheat pump system, one of skill in the art will recognize that othersuitable caloric materials may be used in a similar manner to heat orcool an appliance, i.e., apply a field, move heat, remove the field,move heat. For example, electro-caloric material heats up and cools downwithin increasing and decreasing electric fields. As another example,elasto-caloric material heats up and cools down when exposed toincreasing and decreasing mechanical strain. As yet another example,baro-caloric material heats up and cools down when exposed to increasingand decreasing pressure. Such materials another other similar caloricmaterials may be used in place of or in addition to the magneto-caloricmaterial described below to heat or cool water within an appliance.Thus, caloric material is used broadly herein to encompass materialsthat undergo heating or cooling when exposed to a changing field from afield generator, where the field generator may be a magnet, an electricfield generator, an actuator for applying mechanical stress or pressure,etc.

Referring now to FIG. 1, an exemplary embodiment of a refrigeratorappliance 10 is depicted as an upright refrigerator having a cabinet orcasing 12 that defines a number of internal storage compartments orchilled chambers. In particular, refrigerator appliance 10 includesupper fresh-food compartments 14 having doors 16 and lower freezercompartment 18 having upper drawer 20 and lower drawer 22. Drawers 20,22 are “pull-out” type drawers in that they can be manually moved intoand out of freezer compartment 18 on suitable slide mechanisms.Refrigerator 10 is provided by way of example only. Other configurationsfor a refrigerator appliance may be used as well including applianceswith only freezer compartments, only chilled compartments, or othercombinations thereof different from that shown in FIG. 1. In addition,the heat pump and heat pump system of the present disclosure is notlimited to refrigerator appliances and may be used in other applicationsas well such as e.g., air-conditioning, electronics cooling devices, andothers. Thus, it should be understood that while the use of a heat pumpand heat pump system to provide cooling within a refrigerator isprovided by way of example herein, the present disclosure may also beused to provide for heating applications as well.

FIG. 2 is a schematic view of various components of refrigeratorappliance 10, including a refrigeration compartment 30 and a machinerycompartment 40. In particular, machinery compartment 30 includes a heatpump system 52 having a first or cold side heat exchanger 32 positionedin refrigeration compartment 30 for the removal of heat therefrom. Aheat transfer fluid such as e.g., an aqueous solution, flowing withinfirst heat exchanger 32 receives heat from refrigeration compartment 30thereby cooling contents of refrigeration compartment 30. A fan 38 maybe used to provide for a flow of air across first heat exchanger 32 toimprove the rate of heat transfer from refrigeration compartment 30.

The heat transfer fluid flows out of first heat exchanger 32 by line 44to heat pump 100. As will be further described herein, the heat transferfluid receives additional heat from magneto-caloric material (MCM) inheat pump 100 and carries this heat by line 48 to pump 42 and then tosecond or hot side heat exchanger 34. Heat is released to theenvironment, machinery compartment 40, and/or other location external torefrigeration compartment 30 using second heat exchanger 34. A fan 36may be used to create a flow of air across second heat exchanger 34 andthereby improve the rate of heat transfer to the environment. Pump 42connected into line 48 causes the heat transfer fluid to recirculate inheat pump system 52. Motor 28 is in mechanical communication with heatpump 100, as will be further described.

From second heat exchanger 34, the heat transfer fluid returns by line50 to heat pump 100 where, as will be further described below, the heattransfer fluid loses heat to the MCM in heat pump 100. The now colderheat transfer fluid flows by line 46 to first heat exchanger 32 toreceive heat from refrigeration compartment 30 and repeat the cycle asjust described.

Heat pump system 52 is provided by way of example only. Otherconfigurations of heat pump system 52 may be used as well. For example,lines 44, 46, 48, and 50 provide fluid communication between the variouscomponents of heat pump system 52 but other heat transfer fluidrecirculation loops with different lines and connections may also beemployed. For example, pump 42 can also be positioned at other locationsor on other lines in system 52. Still other configurations of heat pumpsystem 52 may be used as well.

FIGS. 3 through 11 illustrate an exemplary heat pump 100 and componentsthereof, and the use of such heat pumps 100 with heat pump system 52, inaccordance with exemplary embodiments of the present disclosure.Components of heat pump 100 may be oriented relative to a coordinatesystem for heat pump 100, which may include a vertical direction V, atransverse direction T, and a longitudinal direction L all of which maybe mutually perpendicular and orthogonal to one another.

As shown in FIGS. 5 and 6, heat pump 100 includes one or more magnetassemblies 110, each of which creates a magnetic field M. For example, amagnetic field M may be generated by a single magnet, or by multiplemagnets. In exemplary embodiments as illustrated, a first magnet 112 anda second magnet 114 may be provided, and the magnetic field M may begenerated between magnets 112, 114. Magnets 112, 114 may, for example,have opposite magnetic polarities such that they either attract or repeleach other. Magnets 112, 114 of magnet assembly 110 may also be spacedapart from each other, such as along the vertical direction V. A gap 116may thus be defined between first magnet 112 and second magnet 114, suchas along the vertical direction V.

Heat pump 100 may further include a support frame 120 which supportsmagnet assembl(ies) 110. Magnet assembly 110 may be connected to supportframe 120. For example, each magnet 112, 114 of magnet assembly 110 maybe connected to support frame 120. Such connection in exemplaryembodiments is a fixed connection via a suitable adhesive, mechanicalfasteners, and/or a suitable connecting technique such as welding,brazing, etc. Support assembly 120 may, for example, support magnets112, 114 in position such that gap 114 is defined between magnets 112,114.

As illustrated, support frame 120 is an open-style frame, such thatinterior portions of support frame 120 are accessible from exterior tosupport frame 120 (e.g. in the longitudinal and transverse directions L,T) and components of heat pump 100 can be traversed from interior tosupport frame 120 to exterior to support frame 120 and vice-versa. Forexample, support frame 120 may define one or more interior spaces 122.Multiple interior spaces 122, as shown, may be partitioned from eachother by frame members or other components of the support frame 120. Aninterior space 122 may be contiguous with associated magnets 112, 114(i.e. magnet assembly 110) and gap 116, such as along the longitudinaldirection L. Support frame 120 may additionally define one or moreexterior spaces 124, each of which includes the exterior environmentproximate support frame 120. Specifically, an exterior space 124 may becontiguous with associated magnets 112, 114 (i.e. magnet assembly 110)and gap 116, such as along the longitudinal direction L. An associatedinterior space 122 and exterior space 124 may be disposed on opposingsides of associated magnets 112, 114 (i.e. magnet assembly 110) and gap116, such as along the longitudinal direction L. Thus, magnet assembly110 and gap 116 may be positioned between an associated interior space122 and exterior space 124, e.g., along the lateral direction L.

As illustrated in FIGS. 5 and 6, support frame 120 and frame members andother components thereof may include and form one or more C-shapedportions. A C-shaped portion may, for example, define an interior space122 and associated gap 116, and may further define an associatedexterior space 124 as shown.

In exemplary embodiments as illustrated, a support frame 120 may supporttwo magnet assemblies 110, and may define an interior space 122, gap116, and exterior space 124 associated with each of two magnetassemblies 110. Alternatively, however, a support frame 120 may supportonly a single magnet assembly 110 or three or more magnet assemblies110.

Various frame members may be utilized to form support frame 120. Forexample, in some exemplary embodiments, an upper frame member 126 and alower frame member 127 may be provided. Lower frame member 127 may bespaced apart from upper frame member 126 along the vertical axis V.First magnet(s) 112 may be connected to upper frame member 126, andsecond magnet(s) 114 may be connected to lower frame member 127. Inexemplary embodiments, upper frame member 126 and lower frame member 127may be formed from materials which have relatively high magneticpermeability, such as iron.

In some exemplary embodiments, as illustrated in FIGS. 5 and 6, asupport frame 120 may further include an intermediate frame member 128.Intermediate frame member 128 may be disposed and extend between andconnect upper frame member 126 and lower frame member 127, and may insome exemplary embodiments be integrally formed with upper and lowerframe members 126, 127. As shown, multiple interior spaces 122 may bepartitioned from each other by intermediate frame member 128. In someexemplary embodiments, intermediate frame member 128 may be formed frommaterials which have relatively high magnetic permeability, such asiron. In other exemplary embodiments, intermediate frame member 128 maybe formed from materials which have relatively lower magneticpermeability than those of upper and lower frame members 126, 127.Accordingly, such materials, termed magnetically shielding materialsherein, may facilitate direction of magnetic flux paths only throughupper and lower frame members 126, 127 and magnet assemblies 110,advantageously reducing losses in magnetic strength, etc.

Referring again to FIGS. 3 through 11, heat pump 100 may further includea plurality of stages, each of which includes a magneto-caloric material(MCM). In exemplary embodiments, such MCM stages may be provided inpairs, each of which may for example include a first stage 130 and asecond stage 132. Each stage 130, 132 may include one or more differenttypes of MCM. Further, the MCM(s) provided in each stage 130, 132 may bethe same or may be different.

As provided in heat pump 100, each stage 130, 132 may extend, such asalong the transverse direction T, between a first end portion 134 and asecond end portion 136. As discussed herein, working fluid (alsoreferred to herein as heat transfer fluid or fluid refrigerant) may flowinto each stage 130, 132 and from each stage 130, 132 through first endportion 134 and second end portion 136. Accordingly, working fluidflowing through a stage 130, 132 during operation of heat pump 100 flowsgenerally along the transverse direction T between first and second endportions 134, 136 of stages 130, 132.

Stages 130, 132, such as each pair of stages 130, 132, may be disposedwithin regenerator housings 140. Regenerator housing 140 along withstages 130, 132 and optional insulative materials 138 may collectivelybe referred to as a regenerator assembly. As shown in FIGS. 5 and 6, ahousing 140 includes a body 142 which defines a plurality of chambers144, each of which extends along the transverse direction T betweenopposing ends of chamber 144. Chambers 144 of a regenerator housing 140may thus be arranged in a linear array along the longitudinal directionL, as shown. Each stage 130, 132, such as of a pair of stages 130, 132,may be disposed within one of chambers 144 of a regenerator housing 140.Accordingly, these stages 130, 132 may be disposed in a linear arrayalong the longitudinal direction L.

As illustrated, in exemplary embodiments, each regenerator housing 140may include a pair of stages 130, 132. Alternatively, three, four ormore stages 130, 132 may be provided in a regenerator housing 140.

The regenerator housing(s) 140 (and associated stages 130, 132) andmagnet assembly(s) 110 may be movable relative to each other, such asalong the longitudinal direction L. In exemplary embodiments as shown,for example, each regenerator housing 140 (and associated stages 130,132) is movable relative to an associated magnet assembly 110, such asalong the longitudinal direction L. Alternatively, however, each magnetassembly 110 may be movable relative to the associated regeneratorhousing 140 (and associated stages 130, 132), such as along thelongitudinal direction L.

Such relative movement between regenerator housing 140 and an associatedmagnet assembly 110 causes movement of each stage 130, 132 into themagnetic field M and out of the magnetic field M. As discussed herein,movement of a stage 130, 132 into the magnetic field M may cause themagnetic moments of the material to orient and the MCM to heat (oralternatively cool) as part of the magneto-caloric effect. When a stage130, 132 is out of the magnetic field M, the MCM may thus cool (oralternatively heat) due to disorder of the magnetic moments of thematerial.

For example, a regenerator housing 140 (or an associated magnet assembly110) may be movable along the longitudinal direction L between a firstposition and a second position. In the first position (as illustratedfor example in FIGS. 3 and 5), regenerator housing 140 may be positionedsuch that first stage 130 disposed within the regenerator housing 140 iswithin the magnetic field M and second stage 132 disposed within theregenerator housing 140 is out of the magnetic field M. Notably, beingout of the magnetic field M means that second stage 132 is generally orsubstantially uninfluenced by the magnets and resulting magnetic fieldM. Accordingly, the MCM of the stage as a whole may not be activelyheating (or cooling) as it would if within the magnetic field M (andinstead may be actively or passively cooling (or heating) due to suchremoval of the magnetic field M). In the second position (as illustratedfor example in FIGS. 4 and 6), regenerator housing 140 may be positionedsuch that first stage 130 disposed within regenerator housing 140 is outof the magnetic field M and second stage 132 disposed within regeneratorhousing 140 is within the magnetic field M.

Regenerator housing 140 (or an associated magnet assembly 110) ismovable along the longitudinal direction L between the first positionand the second position. Such movement along the longitudinal directionfrom the first position to the second position may be referred to hereinas a first transition, while movement along the longitudinal directionfrom the second position to the first position may be referred to hereinas a second transition.

Referring to FIGS. 8 and 9, movement of a regenerator housing 140 (or anassociated magnet assembly 110) may be caused by operation of motor 26.Motor 26 may be in mechanical communication with regenerator housing 140(or magnet assembly 110) and configured for moving regenerator housing140 (or magnet assembly 110) along the longitudinal direction L (i.e.between the first position and second position). For example, a shaft150 of motor 28 may be connected to a cam. The cam may be connected tothe regenerator housing 140 (or associated magnet assembly 110), suchthat relative movement of the regenerator housing 140 and associatedmagnet assembly 110 is caused by and due to rotation of the cam. The cammay, as shown, be rotational about the longitudinal direction L.

For example, in some exemplary embodiments as illustrated in FIGS. 8 and9, the cam may be a cam cylinder 152. Cam cylinder 152 may be rotationalabout the longitudinal direction L. A cam groove 154 may be defined incam cylinder 152, and a follower tab 148 of regenerator housing 120 mayextend into cam groove 154. Rotation of motor 28 may cause rotation ofcam cylinder 152. Cam groove 154 may be defined in a particularlydesired cam profile such that, when cam cylinder 152 rotates, tab 148moves along the longitudinal direction L between the first position andsecond position due to the pattern of cam groove 154 and in the camprofile, in turn causing such movement of regenerator housing 120.

FIG. 9 illustrates one embodiment of a cam profile which includes afirst position, first transition, second position, and secondtransition. Notably, in exemplary embodiments the period during which aregenerator housing 140 (or an associated magnet assembly 110) isdwelling in the first position and/or second position may be longer thanthe period during which the regenerator housing 140 (or an associatedmagnet assembly 110) is moving in the first transition and/or secondtransition. Accordingly, the cam profile defined by the cam defines thefirst position, the second position, the first transition, and thesecond transition. In exemplary embodiments, the cam profile causes theone of the regenerator housing or the magnet assembly to dwell in thefirst position and the second position for periods of time longer thantime periods in the first transition and second transition.

Referring again to FIG. 2, in some exemplary embodiments, lines 44, 46,48, 50 may facilitate the flow of working fluid between heat exchangers32, 34 and heat pump 100. Referring now to FIGS. 3, 4 and 7, inexemplary embodiments, lines 44, 46, 48, 50 may facilitate the flow ofworking fluid between heat exchangers 32, 34 and stages 130, 132 of heatpump 100. Working fluid may flow to and from each stage 130, 132 throughvarious apertures defined in each stage. The apertures generally definethe locations of working fluid flow to or from each stage. In someexemplary embodiments as illustrated in FIGS. 3, 4 and 7, multipleapertures (e.g., two apertures) may be defined in first end 134 andsecond end 136 of each stage 130, 132. For example, each stage 130, 132may define a cold side inlet 162, a cold side outlet 164, a hot sideinlet 166 and a hot side outlet 168. Cold side inlet 162 and cold sideoutlet 164 may be defined in each stage 130, 132 at first end 134 ofstage 130, 132, and hot side inlet 166 and hot side outlet 168 may bedefined in each stage 130, 132 at second end 136 of stage 130, 132. Theinlets and outlets may provide fluid communication for the working fluidto flow into and out of each stage 130, 132, and from or to heatexchangers 32, 34. For example, a line 44 may extend between cold sideheat exchanger 32 and cold side inlet 162, such that working fluid fromheat exchanger 32 flows through line 44 to cold side inlet 162. A line46 may extend between cold side outlet 164 and cold side heat exchanger32, such that working fluid from cold side outlet 164 flows through line46 to heat exchanger 32. A line 50 may extend between hot side heatexchanger 34 and hot side inlet 166, such that working fluid from heatexchanger 34 flows through line 50 to hot side inlet 166. A line 48 mayextend between hot side outlet 168 and hot side heat exchanger 34, suchthat working fluid from hot side outlet 168 flows through line 48 toheat exchanger 34.

When a regenerator housing 140 (and associated stages 130, 132) is in afirst position, a first stage 130 may be within the magnetic field and asecond stage 132 may be out of the magnetic field. Accordingly, workingfluid in first stage 130 may be heated (or cooled) due to themagneto-caloric effect, while working fluid in second stage 132 may becooled (or heated) due to the lack of magneto-caloric effect.Additionally, when a stage 130, 132 is in the first position or secondposition, working fluid may be actively flowed to heat exchangers 32,34, such as through inlets and outlets of the various stages 130, 132.Working fluid may be generally constant within stages 130, 132 duringthe first and second transitions.

One or more pumps 170, 172 (each of which may be a pump 42 as discussedherein) may be operable to facilitate such active flow of working fluidwhen the stages are in the first position or second position. Inexemplary embodiments, each pump is or includes a reciprocating piston.For example, a single pump assembly may include two reciprocatingpistons. For example, a first pump 170 (which may be or include apiston) may operate to flow working fluid when the stages 130, 132 arein the first position (such that stage 130 is within the magnetic fieldM and stage 132 is out of the magnetic field M), while a second pump 172(which may be or include a piston) may operate to flow working fluidwhen the stages 130, 132 are in the second position (such that stage 132is within the magnetic field M and stage 130 is out of the magneticfield M). Operation of a pump 170, 172 may cause active flow of workingfluid through the stages 130, 132, heat exchangers 32, 34, and system 52generally. Each pump 170, 172 may be in fluid communication with thestages 130, 132 and heat exchangers 32, 34, such as on various linesbetween stages 130, 132 and heat exchangers 32, 34. In exemplaryembodiments as shown, the pumps 170, 172 may be on “hot side” linesbetween the stages 130, 132 and heat exchanger 34 (i.e. on lines 48).Alternatively, the pumps 170, 172 may be on “cold side” lines betweenthe stages 130, 132 and heat exchanger 32 (i.e. on lines 44). Referringbriefly to FIG. 10, operation of the pumps 170, 172 relative to movementof a regenerator housing 140 and associated stages 130, 132 through acam profile is illustrated. First pump 170 may operate when the stagesare in the first position, and second pump 172 may operate when thestages are in the second position.

Working fluid may be flowable from a stage 130, 132 through hot sideoutlet 168 and to stage 130, 132 through cold side inlet 162 when thestage is within the magnetic field M. Working fluid may be flowable froma stage 130, 132 through cold side outlet 164 and to the stage throughhot side inlet 166 during movement of stage 130, 132 when the stage isout of the magnetic field M. Accordingly, and referring now to FIGS. 3and 4, a first flow path 180 and a second flow path 182 may be defined.Each flow path 180 may include flow through a first stage 130 and secondstage 132, as well as flow through cold side heat exchanger 32 and hotside heat exchanger 34. The flow of working fluid may occur either alongthe first flow path 180 or the second flow path 182, depending on thepositioning of the first and second stages 130, 132.

FIG. 3 illustrates a first flow path 180, which may be utilized in thefirst position. In the first position, first stage 130 is within themagnetic field M, and second stage 132 is out of the magnetic field M.Activation and operation of pump 170 may facilitate active working fluidflow through first flow path 180. As shown, working fluid may flow fromcold side heat exchanger 32 through line 44 and cold side inlet 162 offirst stage 130 to the first stage 130, from first stage 130 through hotside outlet 168 and line 48 of first stage 130 to hot side heatexchanger 34, from hot side heat exchanger 34 through line 50 and hotside inlet 166 of second stage 132 to second stage 132, and from secondstage 132 through cold side outlet 164 and line 46 of second stage 132to cold side heat exchanger 32.

FIG. 4 illustrates a second flow path 182, which may be utilized duringthe second position. In the second position, second stage 132 is withinthe magnetic field M, and first stage 130 is out of the magnetic fieldM. Activation and operation of pump 172 may facilitate active workingfluid flow through second flow path 182. As shown, working fluid mayflow from cold side heat exchanger 32 through line 44 and cold sideinlet 162 of second stage 132 to second stage 132, from second stage 132through hot side outlet 168 and line 48 of second stage 132 to hot sideheat exchanger 34, from hot side heat exchanger 34 through line 50 andhot side inlet 166 of first stage 130 to first stage 130, and from firststage 130 through cold side outlet 164 and line 46 of first stage 130 tocold side heat exchanger 32.

Notably, check valves 190 may in some exemplary embodiments be providedon the various lines 44, 46, 48, 50 to prevent backflow there-through.Check valves 190, in combination with differential pressures duringoperation of heat pump 100, may thus generally prevent flow through theimproper flow path when working fluid is being actively flowed throughone of flow paths 190, 192.

For example, flexible lines 44, 46, 48, 50 may each be formed from oneof a polyurethane, a rubber, or a polyvinyl chloride, or anothersuitable polymer or other material. In exemplary embodiments, lines 44,46, 48, 50 may further be fiber impregnated, and thus include embeddedfibers, or may be otherwise reinforced. For example, glass, carbon,polymer or other fibers may be utilized, or other polymers such aspolyester may be utilized to reinforce lines 44, 46, 48, 50.

FIG. 11 illustrates an exemplary method of the present disclosure usinga schematic representation of associated stages 130, 132 of MCM duringdwelling in and movement between the various positions as discussedherein. With regard to first stage 130, during step 200, whichcorresponds to the first position, stage 130 is fully within magneticfield M, which causes the magnetic moments of the material to orient andthe MCM to heat as part of the magneto caloric effect. Further, pump 170is activated to actively flow working fluid in first flow path 180. Asindicated by arrow Q_(H-OUT), working fluid in stage 130, now heated bythe MCM, can travel out of stage 130 and along line 48 to second heatexchanger 34. At the same time, and as indicated by arrow Q_(H-IN),working fluid from first heat exchanger 32 flows into stage 130 fromline 44. Because working fluid from first heat exchanger 32 isrelatively cooler than the MCM in stage 130, the MCM will lose heat tothe working fluid.

In step 202, stage 130 is moved from the first position to the secondposition in the first transition. During the time in the firsttransition, working fluid dwells in the MCM of stage 130. Morespecifically, the working fluid does not actively flow through stage130.

In step 204, stage 130 is in the second position and thus out ofmagnetic field M. The absence or lessening of the magnetic field is suchthat the magnetic moments of the material become disordered and the MCMabsorbs heat as part of the magnetocaloric effect. Further, pump 172 isactivated to actively flow working fluid in the second flow path 182. Asindicated by arrow Q_(C-OUT), working fluid in stage 130, now cooled bythe MCM, can travel out of stage 130 and along line 46 to first heatexchanger 32. At the same time, and as indicated by arrow Q_(C-IN),working fluid from second heat exchanger 34 flows into stage 112 fromline 50 when stage 130 is in the second transition. Because workingfluid from second heat exchanger 34 is relatively warmer than the MCM instage 130, the MCM will lose some of its heat to the working fluid. Theworking fluid now travels along line 46 to first heat exchanger 32 toreceive heat and cool refrigeration compartment 30.

In step 206, stage 130 is moved from the second position to the firstposition in the second transition. During the time in the secondtransition, the working fluid dwells in the MCM of stage 130. Morespecifically, the working fluid does not actively flow through stage130.

With regard to second stage 132, during step 200, which corresponds tothe first position, second stage 132 is out of magnetic field M. Theabsence or lessening of the magnetic field is such that the magneticmoments of the material become disordered and the MCM absorbs heat aspart of the magneto-caloric effect. Further, pump 170 is activated toactively flow working fluid in first flow path 180. As indicated byarrow Q_(C-OUT), working fluid in stage 132, now cooled by the MCM, cantravel out of stage 132 and along line 46 to first heat exchanger 32. Atthe same time, and as indicated by arrow Q_(C-IN), working fluid fromsecond heat exchanger 34 flows into stage 112 from line 50 when stage132 is in the second transition. Because working fluid from second heatexchanger 34 is relatively warmer than the MCM in stage 132, the MCMwill lose some of its heat to the working fluid. The working fluid nowtravels along line 46 to first heat exchanger 32 to receive heat andcool the refrigeration compartment 30.

In step 202, stage 132 is moved from the first position to the secondposition in the first transition. During the time in the firsttransition, the working fluid dwells in the MCM of stage 132. Morespecifically, the working fluid does not actively flow through stage132.

In step 204, stage 132 is in the second position and thus fully withinmagnetic field M, which causes the magnetic moments of the material toorient and the MCM to heat as part of the magneto caloric effect.Further, pump 172 is activated to actively flow working fluid in thesecond flow path 182. As indicated by arrow Q_(H-OUT), working fluid instage 132, now heated by the MCM, can travel out of stage 132 and alongline 48 to second heat exchanger 34. At the same time, and as indicatedby arrow Q_(H-IN), working fluid from first heat exchanger 32 flows intostage 132 from line 44. Because working fluid from first heat exchanger32 is relatively cooler than the MCM in stage 132, the MCM will loseheat to the working fluid.

In step 206, stage 132 is moved from the second position to the firstposition in the second transition. During the time in the secondtransition, working fluid dwells in the MCM of stage 132. Morespecifically, the working fluid does not actively flow through stage132.

FIGS. 12, 13 and 14 provide section views of regenerators according tovarious exemplary embodiment of the present subject matter. As discussedin greater detail below the regenerators shown in FIGS. 12, 13 and 14include features for assisting with providing even flow of working fluidinto the regenerators. Even working fluid flow into the regenerators canlimit or reduce dead fluid volume within the regenerators and/or providemore even fluid flow from the regenerators. The regenerators shown inFIGS. 12, 13 and 14 may be used in any suitable caloric heat pump, suchas heat pump 100 described above.

Turning now to FIG. 12, a regenerator 200 according to an exemplaryembodiment of the present subject matter is provided. Regenerator 200includes a regenerator housing 210 and a stage 220. Regenerator housing210 defines a longitudinal direction LL and a transverse direction TTthat are perpendicular to each other. Regenerator housing 210 may hollowand define a chamber 212 therein. Regenerator housing 210 (e.g., andchamber 212) extends, e.g., along the longitudinal direction LL, betweena first end portion 214 and a second end portion 216. Thus, regeneratorhousing 210 may be hollow between first and second end portions 214, 216of regenerator housing 210, e.g., along the longitudinal direction LL.

Stage 220 includes a caloric material, such as a magneto-caloricmaterial, and is disposed within chamber 212 of regenerator housing 210.In particular, stage 220 may be disposed within chamber 212 ofregenerator housing 210 between the first and second end portions 214,216 of regenerator housing 210. Working fluid may flow through the stage220 between first and second end portions 214, 216 of regeneratorhousing 210 within regenerator housing 210.

Regenerator 200 also includes a pair of caps that assist with sealingchamber 212 of regenerator housing 210 in order to define a flow pathfor working fluid through regenerator 200. In particular, regenerator200 includes a first cap 230 and a second cap 240. First cap 230 andsecond cap 240 are mounted to regenerator housing 210, e.g., such thatfirst cap 230 and second cap 240 are positioned at opposite ends ofregenerator housing 210 along the longitudinal direction LL and/orspaced apart from each other along the longitudinal direction LL. As anexample, first cap 230 is mounted or affixed to regenerator housing 210at first end portion 214 of regenerator housing 210, and second cap 240is mounted or affixed to regenerator housing 210 at second end portion216 of regenerator housing 210.

First cap 230 and second cap 240 may be constructed of any suitablematerial. For example, first cap 230 and second cap 240 may beconstructed of plastic, such as molded or additively formed plastic.Regenerator housing 210 may also be formed of plastic, and first cap 230and second cap 240 may be mounted to regenerator housing 210 using anysuitable method or mechanism, such as screw threads, spin welding,ultrasonic welding, adhesive, etc. In certain exemplary embodiments,first and second caps 230, 240 may be uniformly shaped. In alternativeexemplary embodiments, first and second caps 230, 240 may have differentshapes.

Stage 220 is disposed within chamber 212 between first cap 230 andsecond cap 240. In particular, first cap 230 and second cap 240 maycontact stage 220 within chamber 212 such that stage 220 is held orsupported within chamber 212 between first cap 230 and second cap 240.As shown in FIG. 12, first cap 230 and stage 220 may extend acrosschamber 212 at first end portion 214 of regenerator housing 210.Similarly, second cap 240 and stage 220 may extend across chamber 212 atsecond end portion 216 of regenerator housing 210. Thus, first cap 230,second cap 240 and stage 220 may have common widths, e.g., along thetransverse direction TT. In particular, first cap 230, second cap 240and stage 220 may extend across chamber 212, e.g., along the transversedirection TT, in order to prevent leakage or bypass of working fluidwithin chamber 212 around first cap 230, second cap 240 and/or stage220.

First cap 230 defines an inlet 232 and an outlet 234 that allow flow ofworking fluid through first cap 230. Similarly, second cap 240 definesan inlet 242 and an outlet 244 that allow flow of working fluid throughsecond cap 240. Outlet 232 of first cap 230 and outlet 242 of second cap240 may be positioned at and/or contiguous with chamber 212. Thus,working fluid may flow into or out of chamber 212 via outlet 232 offirst cap 230 and/or outlet 242 of second cap 240, depending upon thedirection of fluid flow through chamber 212.

Inlet 232 of first cap 230 and outlet 234 of first cap 230 each definean area in a respective plane that is perpendicular to the longitudinaldirection LL. Thus, the area of inlet 232 of first cap 230 and the areaof outlet 234 of first cap 230 may be perpendicular to direction of theflow of working fluid through first cap 230 at inlet 232 of first cap230 and outlet 234 of first cap 230. In addition, inlet 242 of secondcap 240 and outlet 244 of second cap 240 each define an area in arespective plane that is perpendicular to the longitudinal direction LL.Thus, the area of inlet 242 of second cap 240 and the area of outlet 244of second cap 240 may be perpendicular to direction of the flow ofworking fluid through second cap 240 at inlet 242 of second cap 240 andoutlet 244 of second cap 240.

The area of inlet 232 of first cap 230 may be less than the area ofoutlet 234 of first cap 230. Similarly, the area of inlet 242 of secondcap 240 may be less than the area of outlet 244 of second cap 240. Suchsizing of the inlets 232, 242 of first and second caps 230, 240 relativeto the outlets 234, 244 of first and second caps 230, 240 may assistwith regulating flow of working fluid through chamber 212 of regeneratorhousing 210 and/or stage 220. For example, such sizing may facilitateeven flow of working fluid into chamber 212 and stage 220, and evenworking fluid flow into chamber 212 and stage 220 can limit or reducedead fluid volume within chamber 212 or stage 220 and/or provide moreeven fluid flow from chamber 212 or stage 220. In particular, the areaof inlet 232 of first cap 230 may be less than the area of outlet 234 offirst cap 230 such that a velocity of working fluid at inlet 232 offirst cap 230 is greater than a velocity of working fluid at outlet 234of first cap 230. Second cap 240 may have similar working fluidvelocities therein.

The area of inlet 232 of first cap 230 may be less than the area ofoutlet 234 of first cap 230 by certain ratios in exemplary embodiments.As an example, the area of outlet 234 of first cap 230 may be at leastfour times greater than the area of inlet 232 of first cap 230. Asanother example, the area of outlet 234 of first cap 230 may be at leastten times greater than the area of inlet 232 of first cap 230. Suchsizing of the area of outlet 234 of first cap 230 relative to the areaof inlet 232 of first cap 230 may assist with significantly reducing thevelocity of working fluid at outlet 234 of first cap 230 relative to thevelocity of working fluid at inlet 232 of first cap 230 and therebylimit or reduce dead fluid volume within chamber 212 or stage 220 and/orprovide more even fluid flow from chamber 212 or stage 220. Features ofsecond cap may be similarly proportioned.

First cap 230 may have various shapes such that area of inlet 232 offirst cap 230 is less than the area of outlet 234 of first cap 230, andsecond cap 240 may have various shapes such that area of inlet 242 ofsecond cap 240 is less than the area of outlet 244 of second cap 240.For example, with reference to FIG. 12, outlet 234 of first cap 230 maybe tapered, e.g., such that the area of outlet 234 decreases along thelongitudinal direction LL from chamber 212 towards inlet 232 of firstcap 230. Thus, outlet 234 of first cap 230 may be conical or otherwisefunneled in certain exemplary embodiments. Still referring to FIG. 12,inlet 232 of first cap 230 may include a plurality of channels 236 thatcollectively define the area of inlet 232 of first cap 230. Channels 236of inlet 232 of first cap 230 may extend towards or outlet 234 of firstcap 230, e.g., along the longitudinal direction LL. In addition,channels 236 may be spaced apart from each other along the transversedirection TT. First cap 230 may include any suitable number of channels236. For example, as shown in FIG. 12, first cap 230 may include twochannels 236. In alternative exemplary embodiments, first cap 230 maydefine three, four, five or more channels 236 or first cap 230 maydefine only one channel.

As shown in FIGS. 13 and 14, caps may have different shapes inalternative exemplary embodiments. A regenerator 300 according toanother exemplary embodiment of the present subject matter is providedin FIG. 13, and a regenerator 400 according to an additional exemplaryembodiment of the present subject matter is provided in FIG. 14.Regenerator 300 and regenerator 400 include similar components and areconstructed in a similar manner to regenerator 200 (FIG. 12). Forexample, regenerator 300 includes a regenerator housing 310, a stage320, a first cap 330 and a second cap 340. Similarly, regenerator 400includes a regenerator housing 410, a stage 420, a first cap 430 and asecond cap 440.

Turning now to FIG. 13, first cap 330 of regenerator 300 has an inlet332 and an outlet 334, and second cap 340 has an inlet 342 and an outlet344. The area of inlet 332 of first cap 330 may be less than the area ofoutlet 334 of first cap 330, and the area of inlet 342 of second cap 340may be less than the area of outlet 344 of second cap 340. The area ofoutlet 334 of first cap 330 may be constant, e.g., along thelongitudinal direction LL between a chamber of regenerator housing 310and inlet 332 of first cap 330. Thus, outlet 334 of first cap 330 may becylindrical or otherwise constant along the longitudinal direction LL incertain exemplary embodiments.

Turning now to FIG. 14, first cap 430 of regenerator 400 has an inlet432 and an outlet 434, and second cap 440 has an inlet 442 and an outlet444. The area of inlet 432 of first cap 430 may be less than the area ofoutlet 434 of first cap 430, and the area of inlet 442 of second cap 440may be less than the area of outlet 444 of second cap 440. Outlet 434 offirst cap 430 defines or includes a plurality of channels 435 thatcollectively define the area of outlet 434 of first cap 430. Channels435 of outlet 434 of first cap 430 extend, e.g., along the longitudinaldirection LL from a chamber of regenerator housing 410 to inlet 432 offirst cap 430. Channels 435 may also be spaced apart from one another,e.g., along the transverse direction TT, within first cap 430. Using theteaching disclosed herein, one of ordinary skill in the art willappreciate that other suitable shapes and arrangements of inlets andoutlets within caps of regenerators may be provides in alternativeexemplary embodiments. For example, caps from regenerator 200,regenerator 300 and regenerator 400 may be combined in any suitablecombination in alternative exemplary embodiments.

This written description uses examples to disclose the invention,including the best mode, and also to enable any person skilled in theart to practice the invention, including making and using any devices orsystems and performing any incorporated methods. The patentable scope ofthe invention is defined by the claims, and may include other examplesthat occur to those skilled in the art. Such other examples are intendedto be within the scope of the claims if they include structural elementsthat do not differ from the literal language of the claims, or if theyinclude equivalent structural elements with insubstantial differencesfrom the literal languages of the claims.

What is claimed is:
 1. A caloric heat pump system, comprising: aregenerator housing comprising a plurality of chambers; a plurality ofstages, each stage comprising a caloric material disposed within arespective chamber of the plurality of chambers; a plurality ofconduits, each conduit coupled to the regenerator housing at arespective one of the plurality of chambers; a pump coupled to theconduits of the plurality of conduits, the pump operable to circulate aworking fluid through the conduits of the plurality of conduits and thestages of the plurality of stages; and a plurality of flow restrictors,each flow restrictor coupled to the regenerator housing or a respectiveone of the plurality of conduits, the flow restrictors of the pluralityof flow restrictors configured such that a flow rate of the workingfluid through each stage of the plurality of stages is uniform.
 2. Thecaloric heat pump system of claim 1, wherein the flow restrictors of theplurality of flow restrictors comprise at least one of an orifice, aneedle valve or a pinch valve.
 3. The caloric heat pump system of claim1, wherein the flow restrictors of the plurality of flow restrictors areorifices and are positioned on the regenerator housing.
 4. The caloricheat pump system of claim 1, wherein the flow restrictors of theplurality of flow restrictors are needle valves or pinch valves and eachflow restrictor is coupled to the respective one of the plurality ofconduits.
 5. The caloric heat pump system of claim 1, wherein theplurality of stages comprises four stages and at least two of the fourstages are plumbed in parallel with the conduits of the plurality ofconduits such that working fluid from the pump simultaneously flowsthrough the at least two of the four stages during operation of thepump.
 6. The caloric heat pump system of claim 5, wherein the pumpcomprises a pair of pistons.
 7. The caloric heat pump system of claim 6,wherein the pump further comprises a cam and a motor, the cam coupled tothe motor such that the cam is rotatable with the motor, each piston ofthe pair of pistons having a follower positioned on the cam.
 8. Thecaloric heat pump system of claim 1, the flow rate of the working fluidthrough each stage of the plurality of stages is within five percent ofone another.
 9. The caloric heat pump system of claim 1, wherein thecaloric material is a magneto-caloric material.
 10. The caloric heatpump system of claim 1, further comprising: a first heat exchanger; anda second heat exchanger separate from the first heat exchanger, whereinthe pump is operable to circulate the heat transfer fluid between thefirst and second heat exchangers and the plurality of stages.
 11. Acaloric heat pump system, comprising: a regenerator housing comprising aplurality of chambers; a plurality of stages, each stage comprising acaloric material disposed within a respective chamber of the pluralityof chambers; a plurality of conduits, each conduit coupled to theregenerator housing at a respective one the plurality of chambers; apump coupled to the conduits of the plurality of conduits, the pumpoperable to circulate a working fluid through the conduits of theplurality of conduits and the stages of the plurality of stages; and aplurality of flow restrictors, each flow restrictor coupled to theregenerator housing or a respective one of the plurality of conduits,the flow restrictors of the plurality of flow restrictors configuredsuch that a flow rate of the working fluid through each stage of theplurality of stages is within five percent of one another, wherein theflow restrictors of the plurality of flow restrictors comprise at leastone of an orifice, a needle valve or a pinch valve.
 12. The caloric heatpump system of claim 11, wherein the flow restrictors of the pluralityof flow restrictors are orifices and are positioned on the regeneratorhousing.
 13. The caloric heat pump system of claim 11, wherein the flowrestrictors of the plurality of flow restrictors are needle valves orpinch valves and each flow restrictor is coupled to the respective oneof the plurality of conduits.
 14. The caloric heat pump system of claim11, wherein the plurality of stages comprises four stages and at leasttwo of the four stages are plumbed in parallel with the conduits of theplurality of conduits such that working fluid from the pumpsimultaneously flows through the at least two of the four stages duringoperation of the pump.
 15. The caloric heat pump system of claim 14,wherein the pump comprises a pair of pistons.
 16. The caloric heat pumpsystem of claim 15, wherein the pump further comprises a cam and amotor, the cam coupled to the motor such that the cam is rotatable withthe motor, each piston of the pair of pistons having a followerpositioned on the cam.
 17. The caloric heat pump system of claim 11,wherein the caloric material is a magneto-caloric material.
 18. Thecaloric heat pump system of claim 11, further comprising: a first heatexchanger; and a second heat exchanger separate from the first heatexchanger, wherein the pump is operable to circulate the heat transferfluid between the first and second heat exchangers and the plurality ofstages.
 19. A method for regulating fluid flow through a plurality ofstages of a caloric heat pump, the method comprising flowing a fluidthrough each stage of the plurality of stages; measuring a flow rate ofthe fluid through each stage of the plurality of stages; and adjusting aplurality of flow restrictors such that the flow rate of fluid througheach stage of the plurality of stages is uniform.
 20. The method ofclaim 19, wherein the flow rate of a working fluid through each stage ofthe plurality of stages is within five percent of one another after saidstep of adjusting.